1. Unit 3
Green and Sustainable Manufacturing Facilities Design and Analysis: Workstation and Material Handling Equipment

2. Ergonomics and Workstation Design Space Requirements
Chapter 7
Ergonomics and Workstation Design Space Requirements

3. Workstation Design Safety and health considerations are now an
integral part of workstation design
The discipline of ergonomics is also
referred to as human factors or human
engineering
Ergonomics is the science of preventing
musculoskeletal injuries in the workplace

4. Workstation Design
Ergonomic injuries are often described by the term "musculoskeletal disorders" or "MSDs"
This term refers to a group of injuries and illnesses that affect the musculoskeletal system
Ergonomic considerations include employee size, strength, reach, vision, cardiovascular capacities, cognition, survivability, and musculoskeletal injuries

5. Workstation Design
The goal is to design the work or workstation so that the task fits the person rather than forcing the human body or psyche to fit the job
Refer to Specific Allowances for Tech 045 project handouts for information on ergonomic considerations
The height of the workbench and angle of the elbows and wrists must be considered to avoid carpal tunnel syndrome problem

6. Workstation Design
A workstation design is normally a top view of the workstation, including the equipment, materials, and operator space
A workstation design must include the following information:
Worktable, machines, and facilities
Incoming materials including quantity and packaging
Outgoing material or finished product
Operator’s space and access to equipment
Location of waste and rejects
Fixture and tools
Scale of drawing

9. Ergonomics & Principles of Motion Economy
Hand motions (should be eliminated as much
as possible, combine motions to eliminate
others, make motions as short as possible,
reduce force, keep both hands equally busy,
use mirror image moves, do not use hand as a
holding device, locate frequently used
tools and materials closer to the point of use)

10. Ergonomics & Principles of Motion Economy
Basic motion types (encourage ballistic
motions; eliminate controlled motions)
Principle 3
Location of parts and tools (have a fixed place
for all parts and tools and have everything as
close to the point of use as possible)

11. Ergonomics & Principles of Motion Economy
Freeing the hands from as much work as
possible (provide other means, such as fixture,
for holding the work)
Principle 5
Gravity (free power; use it)
Principle 6
Operator safety and health considerations

12. Space Determination
Space determination starts with the workstation design
Length X width of each workstation = its square footage
Total or sum of all square footage X 150% (or 200%) = space for all workstations + aisles + work in process + miscellaneous extra room
This space does not include restrooms, lunch rooms, first aid, tool rooms, maintenance, offices, stores, warehouse, shipping, or receiving

13. Space Determination Spreadsheet
Machine
Length X width
Sq Ft X No of Stations
Total square Ft
Milling Machine X X
200
Injection Molding Machine X X
5400
Paint Systems X X
3000
Puch Press X X
120
Assembly X X
800
Total Square Feet
9520
X 150 % = 14280

16. Chapter 10
Material Handling

17. Material Handling Defined
1) All movement of materials in a manufacturing environment (broad definition)
2) The art of and science involving moving, packaging, and storing of substances in any form (American Society of Mechanical Engineers)
3) The function of moving the right material to the right place, at the right time, in the right amount, in sequence, and in the right position or condition to minimize production cost (specific definition)

18. About Material Handling
On the average, material handling accounts for 50% of the total operations cost
Non-powered material handling equipment such as gravity chutes, rollers, hand carts, and hand jacks can be very cost efficient and should always be considered

19. Goal of Material Handling
The primary goal of material handling is to reduce unit costs
Adequate space must be developed for material handling equipment
Safety must be of primary concern in operating material handling equipment

20. Twenty Principles of Material Handling
1) Planning principle 2) System principle
3) Material flow principle 4) Work simplification principle
5) Gravity principle 6) Maximizing building cube principle
7) Unit size principle 8) Mechanization principle
9) Automation principle 10) Equipment selection principle
11) Standardization principle 12) Adaptability principle
13) Dead weight principle 14) Utilization principle
15) Maintenance principle 16) Obsolescence principle
17) Control principle 18) Capacity principle
19) Performance principle 20) Safety principle

21. Material Handling Equipment
Chapter 11
Material Handling Equipment

22. Four groups of material handling equipment
Fixed-path or point-to-point equipment
Fixed-area material handling equipment
Variable-path variable area equipment
Auxiliary tools and equipment

24. Receiving & Moving Dock Material Handling Equipment
Hand carts: Two-wheeled hand truck, pallet hand hack (or pallet truck-hydraulic lift), four-wheeled hand carts, and pallets
Fork trucks
Multipurpose equipment such as lifts and cranes
Telescopic conveyor
Weight scale

26. Stores Material Handling Equipment
Narrow aisle trucks: Reach truck, straddle truck, side shifting lift trucks, maintenance carts, dollies and casters, maintenance tool crib, carousel storage and retrieval systems
Kitting system
Inventory control system

28. Fabrication Material Handling Equipment
Shop containers
Tubs and baskets
Drop bottom tubs
Drop side tubs or baskets
Tilt stands
V stands
Scissor lifts or hydraulic lifts
Dump hopper

30. Workstation Material Handling Devices
Counterbalances
Manipulators and lifting devices
Vibratory feeders
Waste disposal
Walking beams
Ball tables
Powered round tables
Jib cranes
Vacuum or magnetic lifts
Robots

32. Mobile Fabrication Equipment
Slides and chutes
Non-powered skate wheel and roller conveyors
Lift conveyors
Adjustable angle conveyors
Magnetic conveyors
Auger or screw conveyors
Vibratory conveyors
Monorail trolley conveyors
Powered hand trucks

34. Assembly and Paint Material Handling Equipment
Belt conveyors
Powered roller conveyors
Car-type conveyors
Slat conveyors
Tow conveyors
Overhead trolley conveyors
Powered and free conveyors

35. Packout Material Handling Equipment
Box formers
Automatic taping, gluing, and stapling
Palletizers
Pick and place robots
Banding
Stretch wrap

38. Warehousing Material Handling Equipment
Picking carts and tractor-trailer picking carts
Gravity flow bins
Clamp trucks
Rotary conveyor bins
Vertical warehouse and picking cars
Packing station
Shipping containers

39. Applicable Green and Sustainability Design Principles
Principle 1: Inherent Rather Than Circumstantial. Designers need to strive to ensure that all material and energy inputs and outputs are as inherently non-hazardous as possible.
Principle 2: Prevention Instead of Treatment. It is better to prevent waste than to treat or clean up waste after it is formed.
Principle 3: Design for Separation. Separation and purification operations should be designed to minimize energy consumption and materials use.

40. Applicable Green and Sustainability Design Principles
Principle 4: Maximize Efficiency. Products, processes, and systems should be designed to maximize mass, energy, space, and time efficiency.
Principle 5: Output-Pulled Versus Input-Pushed Products, processes, and systems should be “output pulled” rather than “input pushed” through the use of energy and materials.
Principle 6: Conserve Complexity. Embedded entropy and complexity must be viewed as an investment when making design choices on recycle, reuse, or beneficial disposition.

41. Applicable Green and Sustainability Design Principles
Principle 10: Integrate Material and Energy Flows. Design of products, processes, and systems must include integration and interconnectivity with available energy and materials flows.
Principle 12: Renewable Rather Than Depleting. Material and energy inputs should be renewable rather than depleting.

42. Manufacturing Materials and Material Handling Systems
Obi, Chapter 7
Manufacturing Materials and Material Handling Systems

43. Three Forms of Materials

45. Types of Manufacturing Materials
Metals
Ferrous Metals
Nonferrous Metals
Plastics
Thermoplastics
Thermosets
Composites
Ceramics
Wood

46. Properties of Manufacturing Materials
Mechanical Properties
Chemical Properties
Electrical Properties
Physical Properties
Manufacturing Properties

47. Shapes and Nature of Commercially Available Manufacturing Materials
Bars
Tubings
Sheets, plates and foils
Ingots
Preforms
Granules and powders
Coils and reels
Liquid materials
Gaseous materials

49. Types of Material Handling Equipment
Bulk Material Handling Equipment
Workstation Material Handling Equipment
Workstation-to-Workstation Material Handling Equipment
Storage Material Handling Equipment
Assembly and Paint Material Handling Systems